Brake Fluid Plant

FRIGMAIRES BRAKE FLUID MANUFACTURING PLANT

PLANT CAPACITY 2000 LTRS/DAY
TOTAL POWER CONSUMPTION 15KW
REQUIRED INSTALLED POWER 20 KW, 440 V/ 50 Hz, 3 Phase
LABOR REQUIRED Skilled 2 / Unskilled 2 with 1 Plant Chemist
AREA 10X5X5 MTRS LXBXH.

ADVANTAGES OF FRIGMAIRES PLANTS :

  • Single Source responsibility for complete plant design right from Civil-Mechanical-Electrical to Chemical process.
  • Client's scope of work limited to bare minimum.
  • Know how and training based on years of manufacturing experience.
  • Modern Laboratory set up to meet international specifications.
  • Plant design complies with international standards and safety.

ABOUT BRAKE FLUIDS

Automotive brake fluid has many responsibilities. Corrosion protection and lubrication of brake system components are only a portion of the role brake fluid must play. All automobiles that have a hydraulic braking system must use brake fluid in order for the brake system to operate. The type of fluid used can depend on the type of vehicle and the demands of the vehicles brake system. The two most common brake fluids used in the automotive industry are fluids that contain Polyalkylene Glycol Ether and fluid that contains Silicone or Selenium-based Polymer. Both Fluids are common but very different in regards to the manner in which they perform. Fluids containing Polyalklene Glycol Ether are more widely used and are the only fluids that should be used in racing brake systems. Because brake systems may reach extreme temperatures brake fluid must have the ability to withstand these temperatures and not degrade rapidly.

SILICONE BASED FLUID

Fluids containing Silicone are generally used in military type vehicles and because Silicone based fluids will not damage painted surfaces they are also somewhat common in show cars. Silicone-based fluids are regarded as DOT 5 fluids. They are highly compressible and can give the driver a feeling of a spongy pedal. The higher the brake system temperature the more the compressibility of the fluid and this increases the feeling of a spongy pedal. Silicone based fluids are non-hydroscopic meaning that they will not absorb or mix with water. When water is present in the brake system it will create a water/fluid/water/fluid situation. Because water boils at approximately 212° F, the ability of the brake system to operate correctly decreases, and the steam created from boiling water adds air to the system. It is important to remember that water may be present in any brake system. Therefore silicone brake fluid lacks the ability to deal with moisture and will dramatically decrease a brake systems performance.

POLYGLYCOL ETHER BASED FLUIDS

Fluids containing Poly glycol ethers are regarded as DOT 3, 4, and DOT 5.1. These type fluids are hydroscopic meaning they have an ability to mix with water and still perform adequately. However, water will drastically reduce the boiling point of fluid. In a passenger car this is not an issue. In a race car it is a major issue because as the boiling point decreases the performance ability of the fluid also decreases. Poly glycol type fluids are 2 times less compressible than silicone type fluids, even when heated. Less compressibility of brake fluid will increase pedal feel. Changing fluid on a regular basis will greatly increase the performance of the brake system.

FLUID SPECIFICATIONS

All brake fluids must meet federal standard #116. Under this standard is three Department of Transportation (DOT) minimal specifications for brake fluid. They are DOT 3, DOT 4, and DOT 5.1 (for fluids based with Polyalkylene Glycol Ether) and DOT 5 (for Silicone based fluids).

MINIMAL boiling points for these specifications are as follows :

Dry Boiling Point Wet Boiling Point
DOT 3 401°F 284° F
DOT 4 446° F 311° F
DOT 5 500° F 356° F
DOT 5.1 518° F 375° F

Racing brake fluids always exceeds the DOT specifications for dry boiling points. Wet boiling points generally remain the same.

WET VS. DRY BOILING POINT

The term boiling point when used regarding brake fluid means the temperatures that brake fluid will begin to boil.

WET BOILING POINT

The minimum temperatures that brake fluids will begin to boil when the brake system contains 3% water byvolume of the system.

DRY BOILING POINT

The temperatures that brake fluid will boil with no water present in the system.

  • LAB INSTRUMENTS
  • LAB INSTRUMENTS
  • LAB INSTRUMENTS

MOISTURE IN THE BRAKE SYSTEM

Water/moisture can be found in nearly all brake systems. Moisture enters the brake system in several ways. One of the more common ways is from using old or pre-opened fluid. Keep in mind, that brake fluid draws in moisture from the surrounding air. Tightly sealing brake fluid bottles and not storing them for long periods of time will help keep moisture out. When changing or bleeding brake fluid always replace master cylinder caps as soon as possible to prevent moisture from entering into the master cylinder. Condensation, (small moisture droplets) can form in lines and calipers. As caliper and line temperatures heat up and then cool repeatedly, condensation occurs, leaving behind an increase in moisture/water. Over time the moisture becomes trapped in the internal sections of calipers, lines, master cylinders, etc. When this water reaches 212° F the water turns to steam. Many times air in the brake system is a result of water that has turned to steam. The build up of steam will create air pressure in the system, sometimes to the point that enough pressure is created to push caliper pistons into the brake pad. This will create brake drag as the rotor and pads make contact and can also create more heat in the system. Diffusion is another way in that water/moisture may enter the system. Diffusion occurs when over time moisture enters through rubber brake hoses. The use of hoses made from EPDM materials (Ethylene-Propylene-Diene-Materials) will reduce the amount of diffusion OR use steel braided brake hose with a non-rubber sleeve (usually Teflon) to greatly reduce the diffusion process.

THINGS TO REMEMBER

  •       Brake fluids dry boiling point is more important then wet boiling point when used in a racing brake system.
  •       Passenger cars very rarely will undergo a brake fluid change making the wet boiling point more important.
  •       Racing brake system fluid is changed often and a system with fresh fluid will most likely not contain water.
  •       Because of this, racers should be concerned with the dry boiling point.
  •       Racing fluid exceeds DOT 3, 4, and 5.1 dry boiling point specifications.
  •       Never use silicone based fluids in racing brake systems.
  •       Using racing brake fluid will increase performance of the braking system.
  •       Never reuse fluid. ° Never mix types or brands of brake fluid.
  •       Use smaller fluid containers that can be used quicker.
  •       If fluid remains in container be sure to tightly seal and do not store for long periods of time.
  •       Purge system (complete drain) and replace fluid often.
  •       Immediately replace master cylinder reservoir cap following any maintenance.

RECOMENDED RAW MATERIALS

  1.     DEG
  2.     PEG
  3.      COLOUR OIL RED MICROFINE
  4.      PARA PHENYLENE DIAMINE
  5.      TEA (TRIETHANOL AMINE
  6.      MIXED BUTOL PHENOL ANTIOXIDANT

EQUIPMENTS

  1.      MIXER
  2.      FILLING LINE
  3.      GEAR PUMPS
  4.      HOLDING VESSEL
  5.      LAB EQUIPMENT

EQUIPMENT DETAILS

FOLLOWING PARAMETERS CONSIDERED FOR EQUIPMENT AND PLANT DESIGN.

    1. Basis:

    Material to be manufactured Brake Fluid
    Ambient air temperature 35°C
    Atmospheric pressure 760 mm Hg.
    Power characteristics 440V, 50Hz, 3 Phase
    Fuel DIESEL

    2. Operating Data :

    Oil inlet temperature NA
    Oil return temperature NA
    Fuel required NA
    Space requirement Approx. 10L X 5W X 3H MTRS. TOTAL FACTORY AREA 200 SQ MTRS.
    Performance +/- 5%
    Performance +/- 10%

    EQUIPMENT DETAILS

    BRAKE FLUID MIXER :

    A Mixer of 1000 Ltrs. working capacity in SS 304 construction provided with a dished type closed top cover on top of which is mounted a 3HP geared motor drive. The motor is coupled to a SS 304 shaft provided with 2 no's propeller blades for quick mixing of fluids in short intervals. The top cover is provided with 2 no's inlet flanged connections of 25mm dia and one inspection site glass and light glass. The vessel has a flat bottom on which is fitted a SS 304 Ball valve of 50mm and one sampling valve. The mixer is supported on a 3Nos SS pipe legs, which are to be grouted to the floor.

    HOLDING TANK :

    A Holding tank of 2000 Itrs capacity in SS 304 construction provided with a flat type closed top cover. The top cover is provided with 2 no's inlet flanged connections of 25mm dia and one inspection site glass and light glass. The vessel has a flat bottom on which is fitted a SS 304 Ball valve of 50mm and one sampling valve. The tank is supported on a 3 No's SS pipe legs which are to be grouted to the floor.

    GEAR PUMP :

    SS Gear Pumps of size 25 mm driven by a 1 HP Geared motor drive suitable for transferring and pumping of viscous liquids is provided. The pumps are mounted on a steel structure and provided with Ss pipelines, valves and fittings.

    LAB EQUIPMENT :

    Reflux Boiling Point Apparatus Qty. 1 No.
    pH Meter Qty. 1 No.
    Moisture Meter
    Digital weighing scale Qty. 1 No.

    • LAB INSTRUMENTS
    • LAB INSTRUMENTS
    • LAB INSTRUMENTS

    FILLING MACHINE:

    Semi Automatic piston type filling machine with nitrogen flushing arrangement provided with single head filling station suitable for filling of 50m1 can to 1000m1 plastic containers complete with filling hopper and 1 Hp electric motor drive.

    PIPING AND VALVES:

    Complete set of SS piping and valves for above within battery limits.

AUTOMATIC SCREW CAPPING MACHINE 1X.

Machine Details

Model No. FE CAP Auto
Application For tightening of pre threaded PP Caps

Machine Description :

The machine comprises of following components :-

Cap Unscrambler: The caps fed in the unscrambler are properly oriented here. The properly oriented caps are brought out through chute and supported at the end by spring loaded fingers. The Unscrambler is rotary disc type with independent flame proof A.C. geared motor drive.

Capping Unit: The containers as it comes out of the filling station moves into the star wheel, picks up the cap and goes towards the capping head. The caps are subsequently tightened as they move in the central turret on to the bottles to the required torque. The torque can be set to the required level. The capped bottles finally emerge out of the machine through discharge conveyor. The speed can be adjusted by adjusting the mechanical drive system.

No Container No Cap : Necesssary Mechanism shall be provided for no bottle - no cap.

Torque Setting : A unique pneumatic torque setting device shall be provided to facilitate torque setting for different cap sizes. The torque can be set on the dial gauge.

NOTE : The above machines will be supplied with one sets of parts for 1 liter pack. Additional change part will be required for each pack for any change in dimensions of the containers which shall be charged at extra.

Material of Construction : All heavy structures constructed in Mild Steel with epoxy powder coating finish.

  • LAB INSTRUMENTS
  • LAB INSTRUMENTS
  • LAB INSTRUMENTS

FE-2000 AUTOMATIC ONLINE INDUCTION CAP SEALER.

Model : - - FE 2000

Sealing Mode :- Automatic Online Induction Cap Sealer

Designed for easy setup. Configured as a single unit for hassle-free mounting over a conveyor

  • Water Re-circulator sits underneath the machine on the same support mobile trolley for one piece shifting from one production line to another.
  • User-friendly front panel membrane controls.
  • Digital sealing power indicator with retention of last setting in memory.
  • IGBT based power and intelligent controls circuits for maximum efficiency.
  • Built-in monitor circuit ensures safe working parameters (e.g. temperature, water, line voltage drops). In case of malfunction machine shuts off and fault is indicated on the front panel.
  • Efficient sealing head design available in various types e.g. flat head, tunnel head, deep tunnel head, to suit different applications.
  • Potential free contacts provided for alarm circuit in case sealing power drops below preset value.
  • Output rating : 2 KW
  • Input Supply : 230V +/- 10% single phase 50Hz. A.C.

Conveyor: 150mm wide 2.4 mtr long Conveyor, with M.S. Powder coated frame as a extension of filling / capping machine conveyor using the same motor drive of filling and capping machine conveyor.




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